Question $7$C$\mathrm{.}4\mathrm{.}1$A

Discuss and explain the operations design process. $(12)$

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Question $7$C$\mathrm{.}4\mathrm{.}1$B

Discuss the operations design process by referring to the following.

$$ Target market

$$ Number of parts required in the manufacturing process

$$ Standard procedures

$$ Ease of use

$$ Ease of assembly and disassembly

$$ Special features $(6)$

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Question $7$C$\mathrm{.}4\mathrm{.}2$

Briefly list and discuss the main factors to be considered when designing a new product or service. $(6)$

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Question $7$C$\mathrm{.}5\mathrm{.}1$

Define capacity. Describe the capacity of your mine, plant or department in terms of the output $($e$.$g$.$ tons of ore in the case of a mine$)$ that it is designed to produce or services that it can offer. $(2)$ M E T S $-3$ W o r k b o o k C h $7($ U p d a t e d : $29$ J a n $2020)$ Page $16$

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Question $7$C$\mathrm{.}5\mathrm{.}2$

Explain how the following factors will affect the availability of production capacity:

$$ Process design

$$ Product design

$$ Product variety

$$ Product quality

$$ Production scheduling

$$ Materials management

$$ Equipment maintenance

$$ People management $(8)$

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Question $7$C$\mathrm{.}5\mathrm{.}4$

Differentiate between design capacity, effective capacity and actual output. Use the information below to calculate the efficiency and utilisation at a repair workshop of a car dealership:

Design capacity: $100$ vehicles per day

Effective capacity: $80$ vehicles per day

Actual output: $72$ vehicles per day $(5)$

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Question $7$C$\mathrm{.}5\mathrm{.}5$

The No $2$ Rock and Ventilation $($RV$)$ shaft of Deep Levels Gold Mining Ltd was designed to handle $255000$ tons of rock per month. The effective capacity of the mine is$,$ however, only $245000$ tons of rock per month. Calculate the efficiency of this shaft for the past month, when $225000$ tons of rock were hoisted. $(2)$ M E T S $-3$ W o r k b o o k C h $7($ U p d a t e d : $29$ J a n $2020)$ Page $17$

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Question $7$C$\mathrm{.}5\mathrm{.}6$

Differentiate between design capacity, effective capacity and actual output. $(6)$

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Question $7$C$\mathrm{.}5\mathrm{.}7$

Briefly define the following types of inventory:

$$ Finished goods

$$ In transit

$$ Raw materials

$$ Work$-$in$-$process $($WIP$)$

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Question $7$C$\mathrm{.}5\mathrm{.}8$

Explain the objectives of capacity planning. List and discuss a number of capacity planning objectives and issues related to it$.(4)$

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Question $7$C$\mathrm{.}6\mathrm{.}1$

Define a flexible manufacturing system $($FMS$)$ and discuss some of its characteristics. Also list some of its advantages and disadvantages. $($

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$7$C$\mathrm{.}7$ The following short and long questions are based on section $7\mathrm{.}7$Just in time $($JIT$)($METS$-3$: $150-153)$ of the textbook.

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Question $7$C$\mathrm{.}7\mathrm{.}1$

Briefly explain what just$-$in$-$time $($JIT$)$ is$.$ Give one example of where it is applied or where it can be applied at your organisation or an organisation that you are familiar with. $(2)$

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Question $7$C$\mathrm{.}7\mathrm{.}2$

Briefly explain what $$Lean production$$ means. $(2)$

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Question $7$C$\mathrm{.}7\mathrm{.}3$

Provide examples of waste that can be eliminated with a JIT system. $(6)$ M E T S $-3$ W o r k b o o k C h $7($ U p d a t e d : $29$ J a n $2020)$ Page $18$

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Question $7$C$\mathrm{.}8\mathrm{.}1$

Briefly explain the purpose of keeping an inventory of spare parts and material at a mine, plant, factory or power station. $(6)$

Question $7$C$\mathrm{.}8\mathrm{.}2$

Briefly define the following types of inventory costs: $(3)$

$$ Holding cost

$$ Ordering cost

$$ Shortage cost

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Question $7$C$\mathrm{.}8\mathrm{.}3$

Briefly describe the A$-$B$-$C inventory classification system and explain how this system can be used to manage inventory. $(4)$

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You have been appointed as the production manager at a new mid$-$size mine where you are also responsible for the mine store and the management of inventory. Due to its limited size, not all inventory items can be stored in the store where it will be more secure$.$ Some will have to be stored under$-$roof in a fenched$-$in area while others may only be guarded $($by a security guard$).$ Design some operational guidelines for the store overseer using the A$-$B$-$C inventory classification system.